is 15711 (2006): road vehicles - compressed natural gas (cng) … · 2018. 11. 15. · is...
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IS 15711 (2006): Road Vehicles - Compressed natural gas(CNG) fuel system components - performance and general testmethods [TED 26: Automotive vehicles on NCES]
IS 15711:2006
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Indian Standard
ROAD VEHICLES — COMPRESSED NATURAL GAS(CNG) FUEL SYSTEM COMPONENTS —
PERFORMANCE AND GENERAL TEST METHODS
ICS 43.060.40
0 BIS 2006
BUREAU OF INDIAN STANDARDSMANAK BHAVAN, 9 BAHADUR SHAH ZAFAR MARG
NEW DELHI 110002
October 2006 Price Group 3
Reaffirmed - 2011
Automotive Vehicles Running on Non-conventional Energy Sources Sectional Committee. TED 26
FOREWORD
This Indian Standard was adopted by the Bureau of Indian Standards, atler the draft finalized by the AutomotiveVehicles Running on Non-conventional Energy Sources Sectional Committee had been approved by the TransportEngineering Division Council.
In the formulation of this standard considerable assistance has been derived from the following standards issuedby the Automotive Research Association of India and International Organization for Standardization respectively:
AIS 024 (Amd 4 to version 3) ‘Safety and procedural requirements for type approval of CNG operated vehicles’
“AIS-028 ( Version 3) ‘Code of practice for use of CNG fuel in internal combustion engine vehicles’
ISO 15500-2:2001 ‘Road vehicles — Compressed natural gas (CNG) fuel system components — Part 2:Performance-of general test methods’
Considering Indian climatic conditions the Committee responsible for the formulation of this standard decided todeviate from the requirement of 1S0 with respect to the following:
a) Components shall t.zetested at a temperature of –20° instead of -40°C, and
b) Testing at room temperature shall be done at 27 + 5° instead of20 + 5“C.
This standard is one of the series of Indian Standards published on CNG onboard fuel system components. Otherstandards in the series are:
IS No.
15710:2006
15712:2006
15713:200615714:200615715:2006
15716:2006
15717:2006
15718:2006
15719:2006
15720:2006
15721:2006
15722:2006
15723:2006
Title
Road vehicles — Compressed natural gas (CNG) fuel system components — Generalrequirements and definitionsRoad vehicles — Compressed natural gas (CNG) fiel system components — Automaticvalve (Solenoid valve)Road vehicles — Compressed natural gas (CNG) fuel system components — Pressure regulatorRoad vehicles — Compressed natural gas (CNG) fuel system components — Gas/Air mixerRoad vehicles — Compressed natural gas (CNG) fuel system components — Conduit(Ventilation hose)Road vehicles — Compressed natural gas (CNG) fuel system components — CNG high pressurefuel line (Rigid) with end connections [Having pressure exceeding 2.15 MPa (21.5 Bar)]Road vehicles — Compressed natural gas (CNG) fuel system components — Petrol valve(Automatic/Manual)Road vehicles — Compressed natural gas (CNG) fue! system components — CNG high pressure
fuel line (Flexible hose) with end connections (Having pressure exceeding 2.15 MPa)Road vehicles — Compressed natural gas (CNG) fuel system components — Electrical wiring -kit
Road vehicles — Compressed natural gas (CNG) fuel system components — Compartments/Sub-compartmentsRoad vehicles — Compressed natural gas (CNG) fuel system components — Fire retardentmaterial for seat, upholstery, roof and side liningRoad vehicles — Compressed natural gas (CNG) tiel system components — CNG low pressureflexible tiel line with or without end connections (Having pressure not exceeding 2.15 MPa)Road vehicles — Compressed natural gas (CNG) fuel system components — Current limitingdevices
The composition of the Committee responsible for the formulation of this standard is given in Annex A.
For the purpose of deciding whether a particular requirement of this standard is complied with, the final value,
observed or calculated, expressing the result of test or analysis, shall be rounded off in accordance with IS 2:1960‘Rules for rounding off numerical values (revised)’. The number of significant places retained in the rounded offvalue should be the same as that of the specified value in this standard.
AMENDMENT NO. 1 JUNE 2012 TO
IS 15711 : 2006 ROAD VEHICLES — COMPRESSED NATURAL GAS (CNG) FUEL SYSTEM
COMPONENTS — PERFORMANCE AND GENERAL TEST METHODS
(Page 2, clause 6.1.2) — Substitute ‘20 N cm /h (The symbol ‘N’ 3
indicates conversion to normal temperature and pressure condition, NTP, that foris, 760 mm Hg pressure and 0°C temperature)’ ‘20 cm /h (normal)’. 3
(Page 2, clause 6.4.2.1) — Insert the word ‘atleast 8 h’ after ‘conditioned’.
Page clause ( 2, 6.4.2.2) — Insert the word ‘atleast 8 h’ after ‘conditioned’. (Page 2, clause 6.4.2.3) — Insert the word ‘atleast 8 h’ after ‘conditioned’.
(TED 26)Reprography Unit, BIS, New Delhi, India
IS 15711:2006
Indian Standard
ROAD VEHICLES — COMPRESSED NATURAL GAS(CNG) FUEL SYSTEM COMPONENTS —
PERFORMANCE AND GENERAL TEST METHODS
1 SCOPE
1.1 This standard specifies performance and generaltest methods for CNG onboard Iiel system components,intended for use on motor vehicles defined in IS 14272(Part 1), two wheelers and construction equipmentvehicles (CEV).
1.1.1 This standard is applicable to CNG fuel systemcomponents intended to use on vehicles usingcompressed natural gas in accordance with IS 15320(mono-fuel or bi-fuel applications). It is not applicableto the following:
a) Liquefied Natural Gas (LNG) fuel systemcomponents located upstream of, and
including, the vaporizer;
b) Fuel containers;
c) Stationary gas engines; and
d) CNG fuel systems components for thepropulsion of marine craft.
1.1.2 This standard is based upon a service pressurefor compressed natural gas as a fiel at 20 MPa (200 bar)
settled at 15°C. Other service pressures could beaccommodated by adjusting the pressure by theappropriate factor (ratio). For example, a 25 MPa(250 bar) service pressure system will require pressures
to be multiplied by 1.25. All references to pressure areto be considered gauge pressures unless otherwisespecitied.
2 REFERENCES
The following standards contain provisions, which
through reference in this text, constitute provisions ofthis standard. At the time of publication the editionsindicated were valid. All standards are subject to revision
and parties to agreements based on this standard areencouraged to investigate the possibility of applying themost recent editions of the standards indicated below.
IS No.
3400
(Part 4): 1987
(Part6) : 2005/1S01817 :1999
Title
Methods of test for vulcanized
rubbers:
Accelerated ageing (second revision)
Rubbers, vulcanized— Determination
of the effect of liquids (secondrevision)
IS No,
9844:1981
1-4272(Part 1): 1995
15320: 2003/1s0 15403:2000
15710:2006
Title
Methods of testing corrosionresistance of electroplated andanodized aluminium coatings byneutral salt spray test
Automotive Vehicles — Types —Terminology: Part 1 Three and fourwheelers
Natural gas — Designation of the
quality of natural gas for use as acompressed fuel for vehicles
Road vehicles — Compressed naturalgas (CNG) fuel system components
— General requirements anddefinitions
3 TERMS AND DEFINITIONS
For the purposes of this standard, the terms anddefinitions given in IS 15710 shall apply.
4 GENERAL
4.1 Unless otherwise stated, the tests shall be conducted
at room temperature, that is 27 + 5“C.
4.2 Components shall comply with the tests specified
in their relevant specifications, as well as the applicable
tests specified in this standard. Because of the
peculiarities of some components, the”list of tests givenin this standard (see 5 to 15) is not exhaustive. Where
additional tests are required, their provisions are givenin another, relevant standard.
4.3 Unless otherwise specified, all tests shall be
conducted using dry air or nitrogen. Qualified
personnel may also test with natural gas provided that
appropriate safety measures are taken. The dewpoint
of the test gas at the test pressure shall be at thetemperature at which there is no icing, or hydrate or
liquid formation.
4.4 It is recognized that new technology may not be
covered in the relevant specifications of components.
5 HYDROSTATIC STRENGTH
A component shall not rupture when subjected to thefollowing test procedure:
1
IS 15711:2006
Plug the outlet opening of the component and have thevalve seats or internal blocks assume the open position.Apply, with a test fluid, the ,hydrostatic pressurespecified in their relevant specification to the inlet ofthe component for a period of at least 3 min.
The sample used in this test shall not be used for anyother testing.
6 LEAKAGE
6.1 General
6.1.1 Prior to conditioning, purge the component ordevice with nitrogen and then seal it at 30 percent ofservice pressure using nitrogen, dry air or naturalgas.
6.1.2 Conduct all tests while the device is continuouslyexposed to the specified test temperatures. The deviceshall either be bubble-free or have a leakage rate ofless than 20 cm3/h (normal) using the following testmethod.
6.2 External Leakage
6.2.1 Plug each device outlet with the appropriatemating connection and apply the test pressure to theinlet.
6.2.2 Apply pressurized air, nitrogen, or natural gas .tothe test device.
6.2.3 At all.test temperatures, immerse the componentsin a suitable test medium for 2 min or use a helium
vacuum test (global accumulation method) or otherequivalent method.
6.2,4 If there are no bubbles for the specified timeperiod, the sample passes the test. If bubbles aredetected measure the leak rate by an appropriatemethod.
6.3 -Internal Leakage
6.3.1 ‘The internal leakage test is applicable only todevices having a closed position. The aim of this test isto check the pressure tightness of the-closed system.
6.3.2 Connect the inlet or outlet (as applicable) of thedevice, with the appropriate mating connection, while
leaving the opposite connection or connections open.
6.4 Test Conditions
6.4.1 General
The leakage test conditions depend on whether thecomponent is exposed to cylinder pressure or locateddownstream of the first stage of pressure reduction. e
6.4.2 Devices Fxposed to Cylinder Pressure
6.4.2.1 The device shall be conditioned at a low
temperature of –20*C, and pressurized at 75 percentand 2.5 percent of service pressure.
6.4.2.2 The device shall be conditioned at a room
temperature .of 27 + 5°C and pressurized at 2.5 percentand 150 percent of service pressure.
6.4.2.3 The device shall be conditioned at a hightemperature of 85°C or 120°C and pressurized at5 percent and 150 percent of service pressure.
6.4.3 Devices Downstream of the First Stage of
Pressure Reduction
6.4.3.1 The device shall be conditioned at a low
temperature of –20”C, and pressurized at 75 percentand 2.5 percent of working pressure.
6.4.3.2 The device shall be conditioned at a roomtemperature of 27 * 5°C and pressurized at 2.5 percentand 150 percent of working pressure.
6.4.3.3 The device shall be conditioned at a hightemperature of 85°C or 120”C and pressurized at
5 percent and 150 percent of working pressure.
7 EXCESS TORQUE RESISTANCE
A component designed to be connected directly tothreaded fittings shall be capable of withstanding,without deformation, breakage or leakage, a torqueeffort of 150 percent of the rated installation value,according to the following test procedure:
a) Test an unused component, applying thetorque adjacent to the fitting.
b) For a component having a threaded connection
or threaded connections, apply the turningeffort for 15 rein, release it then remove thecomponent and examine it for deformation andbreakage.
c) Subject the component to the leakage testspecified in 6.
8 BENDING MOMENT
A component shall be capable of operation withoutcracking, breaking, or leaking when tested according
to the following procedure:
.a)
b)
2
Assemble the connections of the component,leak-tight to an appropriate mating connection
or connections, representative of design intent.Atler assembly, the length of the inlet tubing
shall b.e greater than 300 mm (see Fig. 1).
The outlet connection shall be rigidlysupported, 25 mm from the component outlet,except in the following cases:
1) If the component has an integral mountingmeans independent of the inlet and outlet
connections, the component shall be
—.. .
1
“1
IS 15711:2006
l@--All dimenslcms in millimetres.
FIG. 1 BENDINGMOMENT
mounted using the integral mountingmeans specified by the manufacturers;
2) If the component is intended to bemounted by either the integral mountingmeans or the component outlet, themounting means that produces the mostsevere test condition shall be used.
c) Check this assembly for leaks prior tosubjecting it to (d).
d) With the component in the closed position,pressurize the system to 5 kPa (50 mbar) andapply a force according to Table 1, 300 mmfrom the inlet, maintaining it for 15 min.Without removing the force, check thecomponent for leakage, in accordance with thetest method given in ‘6, at room temperature.
NOTE — Depending on how this test is performed.raising the load to compensate buoyancy could benecessary.
e) Conduct procedure (d) four times, rotating thecomponent 90° around the horizontal axisbetween each test. Between tests, open andclose (if applicable) the component three timeswith the bending moment removed.
Table 1 Bending Moment Test Force
(Clause 8)
S1 No. Outside Diameter of Tubing Forcemm N
(I) (2) (3)
i) 6 3.4
ii) 8 ?.0iii) 2 12 17.0
5kPa(50mbar)a-—
Key:
1) Component2) Force Pointa 4 x 90° rotation
~ At the completion of the above tests, removethe component and examine it fordeformation; then subject it to the leakage testaccording to 6.
9 CONTINU-ED OPERATION
9.1 General
For the details of test methods for particularcomponents, see their relevant standard. The method
specified in this clause is general in nature and alsoapplies to miscellaneous components.
9.2 Test Method
9.2.1 Test Procedure
Connect the component securely by a suitidble fittingto a pressurized source of dry air, nitrogen or naturalgas and subject it to the number of cycles specified intheir relevant specification. A cycle shall consist of oneopening and (if applicable) one closing of thecomponent within a period of not less than 10 + 2 s.
During the off-cycle, the downstream pressure of thetest fixture shall be lowered to a maximum of 50 percentof the test pressure.
In the case of components downstream of the first stage
of pressure reduction, the test pressure shall be basedon 100 percent of the working pressure.
Unless otherwise specified, the conditions of 9.2.2and 9.2.3 apply.
9.2.2 Room Temperature Cycling
Operate the component through 96 percent of the total
3
IS 15711:2006
cycles at room temperature and at service pressure,according to 6.
> This test may be interrupted, if desired, at 20 percentintervals for leakage testing.
9.2.3 High Temperature Cycling
Operate the component through 2 percent of the totalcycles at the appropriate maximum temperaturespecified in 4.4 of IS 15710, at service pressure. Thecomponent shall comply with 6 at the appropriatemaximum temperature at the completion of the hightemperature cycles.
9.2.4 Low Temperature Cycling
Operate the component through 2 percent of the totalcycles at the appropriate minimum temperaturespecified in 4.4 of IS 15710 at 50 percent servicepressure. The component shall comply with 6 at theappropriate minimum temperature at the completionof the low temperature cycles.
10 CORROSION RESISTANCE
10.1 All components shall perform safely and incompliance with 6 following exposure to salt sprayaccording to the following test method.
10.2 With the component supported in its normalinstalled position, expose it for 96 h to a salt spray
(fog) test as specified in IS 9844.
10.3 Maintain the temperature within the fog chamberat between 33°C and 36°C.
10.4 The saline solution shall consist of 5 percent
sodium chloride and 95 percent distilled water, by weight.
10.5 Immediately following the corrosion test, rinsethe sample and gently clean it of salt deposits; thensubject it to the tests according to 6.
11 OXYGEN AGEING
All synthetic or non metallic parts of components thatprovide a fuel-containing seal for which a satisfactorydeclaration of properties is not submitted by theapplicant shall not crack or show visible evidence of
deterioration after oxygen ageing when tested accordingto the following procedure.
Subject representative samples to 96 h of exposure tooxygen at a temperature of 70”C, at 2 MPa (20 bar)inaccordance with IS 3400 (Part 4).
12 ELECTRICAL OVERVOLTAGES
All electrical components or devices containingelectrical subcomponents shall withstand theapplication of 1.5 times the rated voltage * 5 percentfor periods of 3 min without failure.
13 NON-M-ETALLIC SYNTHETIC IMMERSION
13.1 Non-metallic synthetic material used in a
component shall be subjected by the test agency to thetests described in 13.2 and 13.3, except where theapplicant submits declarations of results of tests carried
out on the material provided by the manufacturer.
13.2 A part made of non-metallic synthetic materialin contact with natural gas shall not show excessive
change in volume or weight when tested according tothe following procedure:
a)
b)
Prepare, measure and weigh a representative
sample or samples of each non-metallicsynthetic material used in a component, thenimmerse the sample or samples at roomtemperature in natural gas at a pressure of20 MPa (200 bar) for a minimum of 70 h.
Following this period of irmnersion, rapidlyreduce the test pressure to atmospheric pressurewithout causing shredding or disintegration.
No tested sample shall exhibit swelling greater than25 percent or shrinkage greater than 1 percent. Theweight change shall not exceed 10 percent.
-13.3 Non-metallic synthetic material used in a
component that could be exposed to ester-based oralpha olefin-based synthetic compressor oi Is, includingnon-synthetic compressor oils, shall not show excessive
change in volume or weight when tested in accordancewith IS 3400 (Part 6) or the following procedure:
a) Prepare, measure and weigh a representativesample or samples of each non-metallicsynthetic material used in a component, thenimmerse the sample or samples at roomtemperature in holders each containing one ofthe test fluids for a minimum of 70 h.
b) Following this period of immersion, removeand measure the test samples.
No sample shall exhibit swelling greater than 25 percentor shrinkage greater than 1 percent. The weight changeshall not exceed 10 percent.
14 VIBRATION RESISTANCE
All components with moving parts shall remain
undamaged, and shall continue to operate and meet therequirements of their leakage tests after 6 h of vibration
carried out according to the following test procedure:
a) Secure the component in a test apparatus andvibrate for 2 h at 17 Hz with an amplitude of1.5 -mm in each of three orientation axes.
b) On completion of this total of 6 h vibration,the component shall comply with therequirements of 6.
4
IS 15711:2006
15 BRASS MATERIAL COMPATIBILITY
All fuel-containing brass components or sub-components for which a satisfactory declaration ofproperties is not submitted by the applicant shall betested according to the following procedure (componentmanufacturers able to provide documentation attestingto the field worthiness of their products are exemptedfrom this requirement).
a) Subject each test sample to the physicalstresses normally imposed on, or within a partas a result of assembly with othercomponents. Apply these stresses to thesample prior to the test and maintain themduring it. Samples with thread, intended tobe used for installing the product in the field,shall have the threads engaged and tightenedto the torque specified in the instructionmanual of the sample. Poly - tetrafluoro
b)
ethylene (PTFE) tape or pipe compoundsshall not be used on the threads.
Degrease three samples and continuously
expose them for 10 d at a set position to a mois~ammonia-air mixture maintained in a glasschamber of approximately 30 litre capacity andwith a glass cover. Maintain approximately
600 cm3 of aqueous ammonia, with a relativedensity (specific gravity) of 0.94 at the bottom
of the glass chamber, below the samples.
Position the samples 40 mm above the aqueousammonia solution, supported by art inert tray.
Maintain the moist ammonia-air mixture.in the
chamber at atmospheric pressure and at a
temperature of 34 + 2“C.
After being subjected to the conditions of thisprocedure, samples shall show no evidence of crackingwhen examined at 25 x magnification.
ANNEX A
(Fmewor@)
COMMITTEE COMPOSITION
Automotive Vehicles Running on Non-conventional Energy Sources Sectional Committee, TED 26
Organization Representative(s)
In personal capacity (D-35, Ham Khas, New Delhi 110016) SHRI B. BHANOT(Chairman)
Automotive Research Association of India, Pune SHRI M. K. CHOUDHARISHRIA. B. KOMAWAR(.41ternate)
Ashok Leyland Ltd, Chennai SHRI NIRMALKUMAR
SHRI G. VISWANATHAN(A/ternate)
Bajaj Auto Ltd, Pune SHRI TAPANBASU
SHRI T. M. BALARAMAN(Alternate)
Batra Associates Limited, Faridabad SHRI N. K. SAWHNEY
Bharat Heavy Electicals Ltd, Bangalore SHRI J. B. D’Souza
SHRI P. S, CNOPRA(Alternate)
Bharat Petroleum Corporation Ltd, Mumbai SHRI R. N. DAS
SHRI N. DASGUPTA(Alternate)
Bombay Environmental Action Group, Mumbai SHRI DEBI GOENKA
Central Institute of Road Transport, Pune SHRI G K. SHARMA
SHRI D. P. SASTE(Alferrzafe)
Central Pollution Control Board, Delhi SHRI T. VENUGOPAL
SHRI RAJESHDEBROY(Ahernate)
Centre for Science and Environment, New Delhi SHRIMATIANUMITAROY
SHRI CHIRAGSHAH (Alternate)
Petroleum & Explosives Safety Organization, Nagpur SHRI A. N. BISWAS
SHRI C. R. SURENORANATHAN(Alternate)
Force Motors Ltd, Pune SHRI S. B. PETHE
SHRI S. V. VIDHWANS(Alternate)
5
IS 15711:2006
Representative(s)Organization
GAIL (hrdia) Limited, New Delhi SHRI S. P. SHARMA
%rra RANV~ERSINGH(Akernafe)
Gujarat Gas Company Limited, Surat SHRI M. 1. V.AKHARWALA
SHRI B. D. JOSHI(Alferrrate)
SHRI S. Y. RAOHindustan Motors Ltd, Sagore
Indian Institute of Petroleum, Dehradun DR MUKESHSAXENA
SHRIA. K. AJGAL(Alterrraie)
Indrapmstha Gas Ltd, New Delhi SHIUP. S. BHARGAVA
SHRJ B. K. NATH (Ahernute)
Mahanagar Gas Ltd, Mumbai SHRJ R. S. PRABHU
Srnu A. UI)EY KIRAN(Wternate)
Mahindra & Mahindra Ltd, Nasik SHRI Z. A. MUIAWAR
SHRJK. V. N. PRASAD(Alternate)
Smu SHNHIRAGRAWAL
SHSUGAGANAGRAWAL(Alfernate)Minda Impco Ltd, New Delhi
Ministry of Non-Conventional Energy Sources, New Delhi
Reliance Industries Limited, Navi Mumbai
DIRECTOR
SHiU N. S. MURTHY
SHRI RAVIV. DESAI (A1/ernate)
SHRI CHETANMAINIReva Electric Car Co (Pvt) Ltd, Bangalore
Rutu Auto Gas Pvt Ltd, Ahmedabad
Sagas Autotech Pvt Ltd, Mysore
SHRI RAJESH KOTHARI
SHRI SANDEEPS. P.
SHRI SANIAYSHYAMANURP. (Alternate)
SHRI N. K. TRWEDi
SHIUB. K. MAITIN(Alternate)Scooters India Ltd, Lucknow
Shri Shakti LPG Ltd, Hyedrabad SHRI JAYAPRAKASHRAMAPPA
Stm CWALAPATHYRAO (Alternate)
Society for Alternate Fuels Aftermarket Conversion, New Delhi SHRJ SANJAYGAMBHIR
SHRJ R. P. KHURANA(Alternate)
Society of Indian Automobile Manufacturers, New Delhi SHRJ K. K. GANDHI
Ms PAMELATnwr (Alternate)
DR KRISHNAIYSNGAR
SHRI P. K. BANERJEE(Alternate)Tat* Motors Ltd, Pune
Transenergy Ltd, Chennai DR K. SRJDHARA
SHIUA. GOPALAKRISHNAN(Alternate)
TVS Suzuki Ltd, Hosur
Vanaz Engineers Ltd, Pune
CAPT N. S. MOHAN RAM
SHRI S. R. SARVATE
SHN S. J. VwPmE (Ahernafe)
Vehicle Research & Development Establishment, Ahmednagar SHRI K. KAMRAJ
SHRJ K. S. JAIN (Alternate)
In personal capacity (D-606, Vashi Plaza, Sector 17, Vashi,
Navi Mumbai 400705)
BIS Directorate General
SHRJALOK CHANDRAGUPTA
SHRJ P. C. JOSHL Scientist ‘E’ and Head (TED)
[Representing Director General (Ex-oficio)]
Member Secretary
SHRJ P. S. MUJRAL
Scientist ‘E’ (TED), BIS
6
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Review of Indian Standards
Amendments are issued to standards as the need arises on the basis of comments. Standards are also reviewedperiodically; a standard along with amendments is reaffirmed when such review indicates that no changes areneeded; if the review indicates that changes are needed, it is taken up for revision. Users of Indian Standardsshould ascertain that they are in possession of the latest amendments or edition by referring to the latest issue of‘BIS Catalogue’ and ‘Standards : Monthly Additions’.
This Indian Standard has been developed from Doc : No. TED 26 (568).
Amendments’Issued Since Publication
Amend No. Date of Issue Text Affected
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